Electromechanical drive device and method for manufacture thereof

ABSTRACT

During the positioning of a control device for controlling an electromechanical drive, contact elements, which are connected to the control device in a fixed manner, are positioned in relation to one or more openings in a connector collar. To position the control device, the latter is displaced into a predetermined position. The predetermined position is defined, for example, by a guide or a stop. The contact elements are a component of an electric and/or optical junction which connects the drive device to other functional units, for example to a door control device or a motor vehicle battery. To position the contact elements in the connector collar of a connecting element which lies on the side of the drive device in the junction, the contact elements are positioned in relation to openings in the connector collar by being displaced together with the control device into the predetermined position. The positioning operation can be automated by a machine, for example by means of corresponding orientation indicators in the drive housing.

CROSS REFERENCE TO RELATED APPLICATION

This application is a National Phase Patent Application of InternationalApplication Number PCT/DE01/01598, filed on Apr. 20, 2001, which claimspriority of German Patent Application Number 100 20 017.6, filed Apr.22, 2000.

BACKGROUND

The invention relates to a method for manufacturing an electromechanicaldrive device for adjusting mechanisms of a motor vehicle, moreparticularly for a window lifter.

In order to raise and lower window panes of a vehicle, electro-motorizedwindow lifters are known which are suitable for installation in motorvehicle doors and which have a drive device in the form of, for example,an electric motor with an attached gearing or gear motor which can beconnected to a vehicle battery through a lead connection and a switch.

The window pane, which can be raised or lowered in the vehicle doorthrough the electromotorized window lifter, is thereby fixed by itslower edge on a guide slide which can be moved up and down along aprofiled rail by means of, for example, a closed cable loop. The cableloop loops around a cable drum which is driven, for example, through aworm gearing by the electric motor in a compact drive device which canhave, in addition to the electric motor and worm gearing, the cable drumand which is fixed on the supporting parts of the inside of the vehicledoor, for example, a support plate, like the profiled rail.

As an alternative to this, the drive device can be used to operate across arm window lifter or other adjusting devices of the vehicle, forexample a length adjustment of a seat.

Since different forces are required for raising and lowering the windowpane, the electric motor is connected to a control device, a control andregulating circuit which is connected to a sensor of a measuring systemfor determining the speed or position of the electric motor. The controldevice for raising or lowering the window pane is operated through anoperating switch by the vehicle driver or passenger.

In DE 198 39 33 C1, a drive device is described for motor vehicleshaving separate housings for the gearing and the associated controlelectronics. The drawback with this drive device is that the modularconstruction requires additional assembly steps for making up thehousing and that the plug connectors between the housings have to beadditionally sealed from moisture.

From EP 0 482 040 B1 an electromechanical drive device is known in whicha conventional plate with structural elements for a control andregulating electronics unit is mounted in a part of the gear housing.The insert module consists of the small plate, a side wall and a plug ofa contact connection fixed on the plate. The insert module is providedwith seals and is inserted until stopping in the part of the gearhousing.

The drawback with this is the number of assembly steps required. First,the connector collar of the contact connection must be completed withcontacts. Second, the connector collar is fixed in the side wall, andthird, the connector contacts are soldered to the plate. In the fourthassembly stage, the side wall has to be provided with a circumferentialseal, and in the fifth step, the insert module is inserted, alignedrelative to the ring magnet, and then fixed.

SUMMARY

The object of the invention is to provide an electromechanical drivedevice which is simple to fit and to provide a method for manufacturingthe electromechanical drive device which is sealed from dirt particlesand fluids, such as for example moisture.

According to this the control device is positioned in the gear housingand the control device is pushed in for positioning through an insertopening in the gear housing. The connector collar is then fixed in or onthe insert opening whereby the contact elements are inserted into thecollar to complete the unit.

For insertion, the control device, for example a circuit substrate,leadframe or module housing of the control device, is guided in guideelements of the gear housing and is positioned, for example snap-fittedin the predetermined position. A particularly quick automated assemblyof the control device can thereby be achieved.

The connector collar consists of at least an insulation material forexample plastics which insulates the individual contact elements fromeach other. In addition other materials for example a metal sleeve forscreening the signal leads can also be provided.

As an alternative for fixing the connector collar, the contact elementsare cast with a sealing compound so that the insert opening togetherwith the contact elements and sealing material form the connectorelement which is on the side of the drive device.

The contact elements inside the insert opening are fixed in positionthrough the sealing compound individually or jointly. No additionalelements are required for the drive side connector element. The edge ofthe insert opening is advantageously formed with elements for keyedconnection with the connector element on the lead element side in orderto increase the mechanical stability of the fitted lead connection.

With both methods according to the invention in order to position thecontrol device, the control device is moved into a predeterminedposition. The predetermined position is, for example, fixed by a guideor a stop. By way of example, any play caused by possible manufacturingtolerances can be compensated by spring elements. Contact elements arefixedly connected to the control device. These contact elements serve tocontact an electrical and/or optical junction which connects the drivedevice to other function units, for example a door control device or avehicle battery. In order that the contact elements can be fixedlyconnected to the control device, metal contact elements can be solderedonto a plate of the control device for example, or the control device isintegrated for example in a switch casing or so-called leadframe, andthe contact elements are fixedly connected in the leadframe by casting.In order to postion the contact elements in the contact collar of aconnecting element of the junction on the side of the drive device, thecontact elements are positioned relative to openings of the contactcollar by being displaced with the control device into the predeterminedposition. The connecting element of the junction on the side of thedrive device is then completed at the same time or subsequently. Thepositioning can be carried out automatically by machine, for example, bycorresponding orientation indicators in the gear housing.

The number of assembly steps is considerably reduced through varioussolutions according to the invention. A conventional plug element, itsseals with the gear casing and the mechanical fixing and electricconnection between the conventional plug element and control device areall unnecessary.

The electric motor has for example a motor shaft connected mechanicallyto the gear, coils for generating commutation and brushes for supplyingcurrent to the coils. The elements of the electric motor are disposed ina motor housing so that the electric motor can be prechecked as afunction unit. The housing of the electric motor is fixed on the gearcasing to make up the electromechanical drive device.

In one embodiment of the invention, the contact collar is connected withmaterial bonding to the gear casing, in which for example the contactcollar is welded ultrasonically to the edge area of the insert openingor the collar is stuck by an adhesive to the edge area around the insertopening. The contact collar can thus be sealed advantageously at thesame time from the gear casing by the materially bonded fastening.

In order to seal the contact collar from particles of dirt and moisturein an advantageous embodiment of the invention the gear housing is castby a sealing compound in the region of the contact collar. Sealingcompounds which can be used for example for electric modules enablescasting under low pressures. Thus in addition to the contact collar thecontrol device can also be cast to seal with pressure-sensitivecomponents such as for example an electrolytic capacitor. In addition tosealing, the cast is also advantageously used for fixing the contactcollar or for the mechanical damping or fixing of the control device orother components.

In order to cast the sealing compound between the contact collar and thecontrol device the contact collar advantageously has in addition atleast one casting opening relative to the openings for the plugcontacts. A cannula or the like is then temporarily inserted in thecasting opening for the duration of casting in order to ensure afavourable distribution of the fluid or paste like sealing compound inthe region of the contact collar.

In a particularly simple method of manufacture the contact elements areformed by conductor panels mounted on a region of a plate, with theirend areas not cast by the sealing compound to allow for later contactconnection. The structural elements connected on the plate are on theother hand advantageously cast with the sealing compound. The conductorpanels are suitably adapted for different requirements. Thus conductorpanels are made for a high current density through a stamped gridtechnique, or copper panels structured on the plate are widened out incross-section for example through galvanic separation of metals. Signalleads are gold-plated for example for lower contact resistance.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be explained in further detail with reference toembodiments illustrated in the drawings in which:

FIG. 1 shows an electromechanical drive device;

FIG. 1 a shows an exploded view of a control device and a connectingelement on the side of the drive device;

FIG. 1 aa shows a detailed view of the exploded view of FIG. 1 a.

DETAILED DESCRIPTION

FIG. 1 shows an embodiment of an electromechanical drive device of awindow lifter. An electric motor A1, here for example a commutator motorA1, is connected mechanically to a gearing. The housing of the electricmotor A1 is fixed to the gear housing A2 through a screw connection A12between the electric motor A1 and the gear housing A2. The gear housingA2 is in this embodiment an injection molded plastic housing, but ametal gear housing can be used as an alternative. The gear housing A2has several screw-in points A20 through which the gear housing A2 isscrewed onto a support plate (not shown in FIG. 1). A driven pinion A29is guided through an opening in the support plate and a cable drum(likewise not shown in FIG. 1) is fixed on the pinion and drives a cableof a window lifter. Inside the gear housing A2 is a gearing, not shownin FIG. 1. The gearing consists for example of a worm connected to theaxis of the electric motor A1 and driving a worm wheel which isconnected to the driven pinion A29.

For controlling the electric motor A1, a control device A5 (shown by wayof example in FIG. 1 a) is integrated in the gear housing A2. Thecontrol device A5 is connected electrically or optically through aconnecting element of a junction on the side of the drive device tofurther function units (not shown) of the vehicle, for example a doorcontrol device or a battery. The connecting element on the side of thedrive device has at least one contact collar A3 and contact elements A4.The contact elements A4 are disposed inside the contact collar A3. Thecontact elements A4 are in this embodiment contact pins A4, but allsuitable types of contact elements A4, such as for example contactsprings, can be used here.

The contact collar A3 serves inter alia for the mechanical stability ofthe connection between the connecting element on the side of the drivedevice and the connecting element on the side of the junction (not shownin FIG. 1). By way of example the contact collar A3 is formed in onepiece with the gear housing A2 by injection moulding the gear housing A2with the contact collar A3. The contact elements A4, shown in FIG. 1 ascontact pins A4, are inserted in the injection moulding tool and thenthe plastic of the contact collar A3 is injected around them.

Electrolytic capacitors A53, shown by way of example in FIG. 1 a, andpressure-sensitive components cannot be injected in the gear casing A2.These are disposed in FIG. 1 in a separate gear housing part A253. Thehousing A253 of the electrolytic capacitor A53 is fixed with materialbonding on the gear housing A2 after the electrolytic capacitor A53 hasbeen connected. The housing A253 of the electrolytic capacitor A53 hasat the same time a second function, a cooling body for diverting thelatent heat from the control device A5 and for this purpose is thermallycoupled to the control device A5.

FIG. 1 a shows in an exploded view a part of the electromechanical drivedevice. In this case the housing A253 of the electrolytic capacitor A53is injection moulded in one piece on the gear housing A2. Theelectrolytic capacitor A53 is connected electrically to the controldevice A5 through the connecting elements and is inserted together withthe control device A5 and the contact pins A4 fixedly connected theretointo the insert opening A25 for positioning. The motor contacts A51 ofthe control device A5 are connected to the electric motor A1 duringpositioning. After insertion the contact pins A4 are adjusted inside theinsert opening A25. The adjustment may be carried out through guideelements (not shown in FIG. 1A) in the gear housing A2. The contactcollar A3 is then inserted at least in part into the insert opening A25whereby the contact pins A4 are guided through openings (A34, FIG. 1aa). The contact collar A3 has casting openings A32 into which a cannula(not shown) is inserted with a sealing compound.

FIG. 1 aa shows a detailed view of the exploded view. A Hall magnet 155is mounted on a worm shaft A115 positioned relative to the controldevice A5. The worm is not shown in FIG. 1 aa. Two Hall sensors areintegrated in the control device A5 to determine the position ormovement of a window pane through the rotation of the Hall magnet A155.The control device A5 is contacted with the connectors A15 of theelectric motor A1 through the motor contacts A51. For this purpose theends of the motor contacts are designed as terminal contacts.

If the contact collar A3 is inserted in the insert opening A25 (FIG. 1a) then the positioned contact pins A4 are inserted in the associatedopenings A34 of the contact collar A3. The contact pins A4 engage in thecontact collar A3 by detent connecting elements A43. Openings A320 inthe contact collar A3 which are not in use can serve additionally tocast around the contact pins A4 with sealing compound, (not shown inFIG. 1 aa).

1. A method for manufacturing an electromechanical drive device foradjusting mechanisms in motor vehicles, wherein a gear is mounted in agear housing and an electric motor is connected mechanically to thegear, comprising: positioning a control device for controlling theelectric motor and at the same time positioning contact elements fixedlyconnected to the control device relative to one or more openings of acontact collar in order to make up a connecting element of a junction ona side of the drive device; positioning the control device in the gearhousing by inserting the control device through an insert opening into ahousing of the gear housing, said housing being integrally connected tothe gear housing; inserting the contact collar at least in part into theinsert opening, thereby inserting the contact elements in the contactcollar; and fixing the contact collar to the insert opening of thehousing, thereby enclosing the control device in said housing of thegear housing, wherein the fixing includes connecting the contact collarto the gear housing using material bonding or a keyed engagement.
 2. Themethod according to claim 1 wherein inserting the control deviceincludes electrically connecting the control device to the electricmotor through connecting of motor contacts.
 3. The method according toclaim 1 wherein the gear housing is cast by a sealing compound in theregion of the contact collar.
 4. The method according to claim 3 whereina fluid or paste like sealing compound is cast through an additionalcasting opening of the contact collar through a cannula.
 5. The methodaccording to claim 1 wherein fixing includes connecting the contactcollar with material bonding to the gear housing by ultrasonic weldingthe contact collar to the edge region of the insert opening.
 6. Themethod according to claim 1 wherein fixing includes connecting thecontact collar with material bonding to the gear housing by sticking thecontact collar to the edge area of the insert opening.
 7. The methodaccording to claim 1 wherein fixing includes connecting the contactcollar to the gear housing through keyed engagement by clipping thecontact collar in the insert opening.
 8. A method for manufacturing anelectromechanical drive device for adjusting mechanisms in motorvehicles, wherein a gear is mounted in a gear housing and an electricmotor is connected mechanically to the gear, comprising: positioning acontrol device for controlling the electric motor and at the same timepositioning contact elements fixedly connected to the control devicerelative to one or more openings of a contact collar in order to make upa connecting element of a junction on a side of the drive device;positioning the control device in the gear housing by inserting thecontrol device through an insert opening into a housing of the gearhousing, said housing being integrally connected to the gear housing;and casting the contact elements with a sealing compound, therebysealing said housing of the gear housing and enclosing the controldevice in said housing so that the insert opening forms with the contactelements and the sealing compound the connecting element on the driveside.
 9. A method according to claim 1 or claim 8 wherein the contactelements are formed by conductor panels mounted on an area of a smallplate.
 10. An electromechanical drive device made according to themethod according to claims 1 or 8 wherein the contact collar is fixed asa separate part on the gear housing.
 11. The electromechanical drivedevice according to claim 10, further comprising a seal mounted in aregion of the contact collar for scaling the insert opening or thecontact collar.
 12. The electromechanical drive device according toclaim 11 wherein the seal is formed by a sealing compound cast in theinsert opening in the region of the contact collar.
 13. Theelectromechanical drive device according to claim 11 wherein the seal isformed by a sealing element of a counter contact.